Impact sound insulation

ABSTRACT

A substrate for use in a flooring system which has a subfloor and a decorative upper layer. The substrate is made in a continuous sheet which has a bottom surface, a top surface, side surfaces and end surfaces. The top surface and the oppositely facing bottom surface are essentially parallel to each other and are spaced apart by the thickness of the substrate. Voids are provided in the substrate, the voids are provided between particles of rubber or other similar material. When the substrate is positioned between the subfloor and the decorative top layer, the particles of rubber provide the strength required to prevent deformation of the substrate in the direction of the thickness and the voids contribute to the sound dampening characteristics required to provide decibel reduction across the thickness of the substrate.

FIELD OF THE INVENTION

The invention is directed to sound insulating material for use inflooring. In particular, a sound insulating material which exhibits thestrength characteristics required to properly support the decorative toplayer of the flooring.

BACKGROUND OF THE INVENTION

Ceramic, masonry, and wood tiles have been used for many years in theconstruction industry. These materials are used for many reasonsincluding strength, durability, and appearance. However, despite theirnumerous desirable qualities, these materials typically exhibit pooracoustic properties. Poor sound or acoustic properties are extremelyundesirable in all structure, but in particular in high-rise buildingswhich are used as office buildings, hotels, apartments, and the like. Asthe occupants of one floor do not want to be disturbed from theoccupants of the floor above, it is typical to add insulating materialbetween the subfloor and the decorative tiles. In fact, standards havebeen developed and modified to insure that sound is not transmitted. TheASTM Impact Sound related tests are E492-90 and E 989-89. Where noisecodes exist, generally IIC50 is specified. These apply to eitherfinished floors of wood, ceramic, tile, stone, marble, vinyl, carpet,laminate, or floating floors of gypsum, lightweight concrete, mortarbeds, plywood, and backer board.

While the insulating material of the prior art dampens the impact soundtransmission, several disadvantages have been associated with the use ofthe insulating material. There are currently a variety of impact soundinsulating materials which achieve the impact sound dampening required.It is typical for these materials to utilize numerous air-filled cells,such as foams, a honeycomb construction, one or more fibrous layers, ora combination of these constructions. All of these have problemsassociated therewith. Increased thickness associated with thesematerials is a significant problem. The thicker the material, thegreater thickness of the floor. Moreover, the increased thickness of thefloor increases the overall height required for the building, therebysignificantly increasing the cost of materials and construction.

Additionally, as many of the materials are designed to reduce impactsound, the structural stability of the material is weak. In other words,the material can easily be compressed when a force is applied thereto.Consequently, while the materials described above work well in ceilingsand walls, structural support must be added in order for the insulatingmaterials to be used in flooring systems. Without the support, the tileswould crack and deform as pressure is applied. The introduction of thesupport layer further adds to the height requirements, resulting ingreater expense.

It would, therefore, be beneficial to provide an insulating member whichprovides the acoustic properties required while providing the structuralsupport necessary to support the tiles. It would also be beneficial toprovide the properties needed while minimizing the height required forthe insulating member.

SUMMARY OF THE INVENTION

An object of the present invention is to provide an insulating materialfor use with decorative flooring tile and the like which minimizes theheight required. Another object of the invention is to provide aninsulating material which has the acoustic properties and the strengthcharacteristics required to be used in a flooring system.

These and other objects are accomplished by the flooring systemdescribed herein. The flooring system has a subfloor, a decorative toplayer, and a substrate provided therebetween. The substrate has a topsurface and an oppositely facing bottom surface. The bottom surfacepositioned proximate the subfloor and the top surface is positionedproximate the decorative top layer. Voids are provided in the substratewhich extend between the top surface and the bottom surface. Thesubstrate is manufactured from rubber in sheets which are cut to thedesired configuration. The substrate has the strength characteristics tosupport the decorative layer and prevent damage thereto and the sounddampening characteristics to provide decibel reduction through thesubstrate.

The invention is also directed to a substrate for use in a flooringsystem which has a subfloor and a decorative upper layer. The substrateis made in a sheet which has a bottom surface, a top surface, sidesurfaces and end surfaces. The top surface and the oppositely facingbottom surface are essentially parallel to each other and are spacedapart by the thickness of the substrate. Voids are provided in thesubstrate, the voids are provided between particles of rubber or othersimilar material. When the substrate is positioned between the subfloorand the decorative top layer, the particles of rubber provide thestrength required to prevent deformation of the substrate in thedirection of the thickness and the voids contribute to the sounddampening characteristics required to provide decibel reduction acrossthe thickness of the substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a substrate according to the presentinvention.

FIG. 2 is an enlarged cross sectional view of the substrate of FIG. 1.

FIG. 3 is a cross sectional view of a flooring system in which thesubstrate of FIG. 1 is incorporated.

DETAILED DESCRIPTION OF THE EMBODIMENT SHOWN

Referring to FIG. 3, a flooring system 2 according to the presentinvention is shown. The flooring system 2 has a base or subfloor 4. Thesubfloor 4 is an integral part of the building or structure and can bein the form of a concrete slab, plywood floor, or any other knownmaterial commonly used in the building industry. Positioned above thesubfloor is a sound absorbing substrate 6 and decorative top layer 7.The sound absorbing substrate 6 may be affixed to the subfloor 4 and/orthe decorative top layer 7 by means of mastic or glue layers 20. As theuse of mastics or glues are well known in the industry, a furtherexplanation of the glue will not be provided.

The decorative top layer may be wood, linoleum, ceramic tile, carpet, orany other known flooring. Individual components of the decorative toplayer 7 are positioned in place and secured to each other by frictionalengagement, glue, grout, or other conventional means. As decorativeflooring is commonly used, a further explanation of the specificsrelating to the decorative top layer 7 will not be provided.

Referring to FIGS. 1 and 2, the substrate 6 has a bottom surface 8, atop surface 10, side surfaces 12 and end surfaces 14. The top surface 10and the oppositely facing bottom surface 8 are essentially parallel toeach other and are spaced from each other by a distance or thickness t.The side surfaces 12 are spaced from each other and are essentiallyparallel to each other. End surfaces 14 are cut to conform to the shaperequired for the particular application. As the substrate ismanufactured in continuous sheets, the length of the substrate will begoverned by the particular installation. This provides maximumflexibility to the installer of the substrate. The use of a continuoussheet of substrate provides advantages which will be more fullydescribed below. Voids 16 are provided in the substrate 6 and arerandomly positioned in the substrate. The size and configuration ofrespective voids is also random.

In the embodiment shown the substrate 6 is manufactured from recycledrubber. During the manufacturing process SBR and natural rubber aremixed with a polyurethane and cured under moderate temperature to form alarge cylindrical member of the rubber. In order to provide a continuoussheet of the substrate 6, the substrate 6 is cut from a cylindricalmember. As the cylindrical member is rotated, blades engage an outsidelayer of the cylindrical member and cause the outside layer to be cutaway from the cylindrical member, thereby forming a continuous sheet ofthe substrate 6. This process of manufacturing the substrate issignificantly different than the vulcanized method generally used tomanufacture substrates of this type. Therefore, the substrate of thepresent invention has greater resiliency, as will be more fullydiscussed below. Although the embodiment shown has a large percentage ofSBR rubber therein, the substrate 6 can be made of SBR rubber, otherrubbers, or any combination thereof.

During installation of the flooring system, at least one continuoussheet of the substrate 6 is brought to the job and cut to theappropriate length. As the rubber material of the present invention hasnot been vulcanized, the rubber material has the flexibility required toallow the rubber material to be delivered in rolls of sheets. With thesubstrate 6 cut to the proper length, the substrate is positioned overand covers the subfloor 4. As each sheet of the substrate 6 is generallyfour feet wide, several sheets of substrate may be required to fullycover the subfloor 4. The use of continuous sheets eliminates many ofthe seams found in the prior art. Previously, individual pieces of sometype of substrate would be positioned on the subfloor. The use of manyrectangular pieces requires many seams which are difficult to alignprecisely, thereby causing gaps to be provided therebetween. The use ofthe sheets minimizes this problem.

The substrate 6 may or may not be glued or secured to the subfloor 4. Ifglue or adhesive 20 or the like is to be used, the glue is generallyapplied to the subfloor prior to the substrate being finally positionedthereon. As the substrate 6 is in the form of continuous sheets, theweight of the sheets and their frictional interface with the subfloor isgenerally sufficient to maintain the substrate in position, therebyeliminating the need for glue 20 or the like.

With the substrate 6 properly positioned on the subfloor 4, thedecorative top layer 7 can be installed. Depending on the material usedfor the decorative top layer, the material may or may not be glued orsecured to the substrate. If glue or adhesive 20 is to be used, the glueis generally applied in small areas and the decorative top layer isinstalled thereon. This process is repeated until the entire decorativetop layer is installed.

In the embodiment shown, the substrate 6 has a density of below 1000kilograms per meter cubed and a decibel reduction of approximately 20 dBfor a substrate having a thickness of 5 mm and 25 dB for a substratehaving a thickness of 10 mm. However, the density and thickness of thesubstrate 6 may be varied according to the particular application.Consequently, the density and material of the substrate are important tothe overall effectiveness of the flooring system. The flooring systemmust have the structural integrity to prevent cracking or breaking ofthe decorative upper layer. Generally, in order to achieve the maximumstructural integrity, the substrate should be as rigid as possible. Infact in many of the previous flooring systems, extra support members areprovided to enhance the rigidity characteristics of the substrate.However, the substrate must also have the ability to dampen the soundand provide the appropriate decibel reduction. In order to achieve thisresult, the prior art teaches of sound dampening materials used in thesubstrate. These materials generally have air voids and the like todampen the sound, which lessens the rigidity of the substrate.Therefore, prior art substrates are either extremely thick or requirethe use of a separate support member to provide the strength and/orsound dampening characteristics required.

In contrast, the substrate 6 of the present invention is configured toachieve the sound dampening and strength requirements with a relativelythin cross section and without the need for an additional supportmember. As the substrate 6 is manufactured as described above, therubber provides the structural integrity required. Although thesubstrate is flexible, when a force is applied to the top surface 10 ofthe substrate 6, the rubber particles 30 will compress only a relativelysmall amount. Therefore, as the compression of the substrate in the ydirection is not great, the movement of the decorative upper layer 7 inthe y direction is also not significant. Consequently, the likelihood ofdamage to the upper layer because of cracking and the like isessentially eliminated. However, the substrate 6 also has the sounddampening characteristics required. As the manufacturing processprovides random voids 16 between the particles of rubber, theconfiguration of the substrate 6 dampens the sound.

The use of substrate 6 has various advantages over the prior art. Unlikeother materials used to dampen sound, the rubber sheets are highlyelastic with long lasting flexibility. The material does not wear,harden, or grow bittle over time. Consequently, as the substratemaintains its integrity and characteristics over time, the decorativetop layer 7 does not wear as quickly and thereby extends the life of thetop layer 7.

The rubber substrate 6 is also moisture insensitive compared to othermaterials such as cork. Therefore, in environments where the floorsystem is exposed to liquids, the performance of the rubber substrate 6will be unaffected by the liquid and will not degrade over time.

As described, the use of sheets provides a solid surface on which thetop layer is positioned. In previous systems, the substrate would bemade from numerous squares (or rectangles) which would be positioned inabutting relationship. If any of the individual pieces were not properlyaligned, a gap or space would be provided between the pieces. While thetop layer positioned over the spaces, the spaces would not properlysupport the top layer, creating a weak area in which the top layer couldcrack over time.

The use of the rubber substrate 6 also allows radiant heat to bepositioned in the floor. As the rubber is stable over a range oftemperatures, the present invention can be used with radiant heatsystems. Many other sound dampening materials would not be adaptablewith radiant heat.

As the substrate does not require additional support members and as thethickness of the substrate can be minimized to accommodate theparticular application, the use of the substrate minimizes the overallheight of the flooring system. This can be an extremely important factorin reducing the cost to construct a building or the like. When comparedwith conventional flooring system currently used, the use of theflooring system described herein can eliminate approximately 13 to 14millimeters of height. As the thickness of the substrate is minimizedand as no additional members are required, the use of the substrate 6reduces the space required. This reduction of height required for theflooring system is particularly significant in multi-story or high risebuildings. In these buildings, a reduction of a meter or less in heightreduces the amount of building material used and is a significant costsavings.

The foregoing illustrates some of the possibilities for practicing theinvention. Many other embodiments are possible within the scope andspirit of the invention. It is, therefore, intended that the foregoingdescription be regarded as illustrative rather than limiting, and thatthe scope of the invention is given by the appended claims together withtheir full range of equivalents.

1. A flooring system comprising: a subfloor; a decorative top layer; asubstrate having a top surface and an oppositely facing bottom surface,the bottom surface positioned proximate the subfloor and the top surfaceis positioned proximate the decorative top layer, the substrate having athickness of about 10 mm and voids which extend between the top surfaceand the bottom surface, the substrate is manufactured from rubber insheets which are cut to the desired configuration; whereby the substratehas the strength characteristics to support the decorative layer andprevent damage thereto and the sound dampening characteristics toprovide decibel reduction through the substrate.
 2. The flooring systemas recited in claim 1 wherein the density of the substrate is less than1000 kilograms per meter cubed.
 3. The flooring system as recited inclaim 1 wherein the substrate has the strength characteristics requiredto support the decorative layer while having sufficient resiliency toallow the substrate to be delivered in rolls.
 4. The flooring system asrecited in claim 1 wherein the substrate is fixed to the subfloor bymeans of an adhesive.
 5. The flooring system as recited in claim 1wherein the substrate is fixed to the decorative top layer by means ofan adhesive.
 6. The flooring system as recited in claim 1 wherein thesubstrate is made from an SBR rubber material.
 7. The flooring system asrecited in claim 1 wherein the sound damping characteristics exhibit adecibel reduction of approximately 20 dB for a substrate with athickness of 5 mm.
 8. A substrate for use in a flooring system which hasa subfloor and a decorative upper layer, the substrate comprising of: acontinuous sheet having a bottom surface configured for frictionalinterface with the subfloor, a top surface configured for receiving thedecorative upper layer, side surfaces and end surfaces, the top surfaceand the oppositely facing bottom surface are essentially parallel toeach other and are spaced apart by the thickness of the substrate, thethickness of the substrate being about 10 mm; an adhesive located on thebottom surface for fixing the substrate to the subfloor; voids areprovided in the substrate, the voids are provided between particles ofmaterial of the substrate, such that the particles of material providethe strength required to prevent deformation of the substrate in thedirection of the thickness and the voids contribute to the sounddampening characteristics required to provide decibel reduction acrossthe thickness of the substrate; and the top surface has an adhesive forfixing the substrate to the decorative upper layer.
 9. The substrate foruse in a flooring system as recited in claim 8 wherein the continuoussheet is cut to the appropriate length to fit the space requirements.10. The substrate for use in a flooring system as recited in claim 8wherein the density of the substrate is less than 1000 kilograms permeter cubed.
 11. The substrate for use in a flooring system as recitedin claim 8 wherein the substrate has the strength characteristicsrequired to support the decorative layer while having sufficientresiliency to allow the substrate to be delivered in rolls.
 12. Thesubstrate for use in a flooring system as recited in claim 8 wherein thesubstrate is made from an SBR rubber material.
 13. The substrate for usein a flooring system as recited in claim 8 wherein the sound dampeningcharacteristics exhibit a decibel reduction of approximately 20 dB for asubstrate with a thickness of 5 mm.
 14. The flooring system as recitedin claim 1 wherein the rubber is formed in a cylindrical member and thesheets are cut from the cylindrical member.
 15. The substrate for use ina flooring system as recited in claim 8 wherein the continuous sheet iscut from a cylindrical member.
 16. The substrate for use in a flooringsystem as recited in claim 8 wherein the substrate includes a binder andparticles of rubber, the binder and the particles of rubber beingpartially severed at the top surface and the bottom surface of thecontinuous sheet.
 17. A flooring system comprising: a subfloor; adecorative top layer; and a rubber substrate having a density of below1000 kilograms per meter cubed and a top surface and an oppositelyfacing bottom surface, the bottom surface positioned proximate thesubfloor and the top surface positioned proximate the decorative toplayer, the substrate having voids which extend between the top surfaceand the bottom surface, wherein the substrate: is manufactured fromrubber in sheets which are cut to the desired configuration, hasstrength characteristics to support the decorative layer and preventdamage thereto, and wherein the flooring system: has sound dampeningcharacteristics to provide decibel reduction through the substrate ofabout 20 dB for a substrate having a thickness of 5 mm and about 25 dBfor a substrate having a thickness of 10 mm; and wherein the substrateis fixed to the decorative top layer by means of an adhesive.
 18. Theflooring system as recited in claim 17, wherein the substrate has thestrength characteristics required to support the decorative layer whilehaving sufficient resiliency to allow the substrate to be delivered inrolls.
 19. The flooring system as recited in claim 17, wherein thesubstrate is fixed to the subfloor by means of an adhesive.
 20. Theflooring system as recited in claim 17, wherein the substrate comprisesan SBR rubber material.
 21. The flooring system as recited in claim 17,wherein said rubber substrate comprises rubber and polyurethane.
 22. Amethod for installation of a flooring system comprising a subfloor, arubber substrate, and a decorative top layer, said method comprising:cutting a continuous sheet of said rubber substrate to a desired length;and positioning the substrate over a subfloor, wherein the rubbersubstrate has a density of below 1000 kilograms per meter cubed and atop surface and an oppositely facing bottom surface, the rubbersubstrate having voids which extend between the top surface and thebottom surface and strength characteristics to support a decorativelayer and prevent damage thereto, said flooring system having sounddampening characteristics to provide decibel reduction through thesubstrate of about 20 dB for a substrate having a thickness of 5 mm andabout 25 dB for a substrate having a thickness of 10 mm; and wherein thesubstrate is fixed to the decorative top layer by means of an adhesive.23. The method as recited in claim 22, wherein the substrate has thestrength characteristics required to support the decorative layer whilehaving sufficient resiliency to allow the substrate to be delivered inrolls.
 24. The method as recited in claim 22, wherein the substrate isfixed to the subfloor by means of an adhesive.
 25. The method as recitedin claim 22, wherein the substrate comprises an SBR rubber material. 26.The method as recited in claim 22, wherein said rubber substratecomprises rubber and polyurethane.
 27. The method according to claim 22,further comprising positioning a decorative layer on the rubbersubstrate.
 28. The method according to claim 27, wherein the positioninga decorative layer includes positioning the decorative layer directly onthe rubber substrate.
 29. The method according to claim 22, furthercomprising providing the continuous sheet of rubber substrate in theform of a rolled sheet.
 30. The method according to claim 29, whereinthe providing the continuous sheet of rubber substrate in the form of arolled sheet includes providing a rolled sheet that is four feet wide.31. The method according to claim 29, wherein the providing a continuoussheet of a rubber substrate includes providing a non-vulcanized rubbersubstrate.
 32. A rubber substrate for use in a flooring system which hasa subfloor and a decorative upper layer, the substrate comprising: acontinuous rubber sheet having a density of less than 1000 kilograms permeter cubed comprising rubber and polyurethane and having a bottomsurface configured for frictional interface with the subfloor, a topsurface configured for receiving the decorative upper layer, sidesurfaces and end surfaces, the top surface and the oppositely facingbottom surface being essentially parallel to each other and spaced apartby the thickness of the substrate, the rubber sheet being nonvulcanizedand having adhesive located on the bottom surface thereof for fixing thesubstrate to the subfloor; wherein voids are provided in the rubbersheet between particles of rubber such that the particles provide thestrength required to prevent deformation of the substrate in thedirection of the thickness and the voids contribute to the sounddampening characteristics required to provide decibel reduction acrossthe thickness of the substrate; and the top surface has an adhesive forfixing the substrate to the decorative upper layer.
 33. The substratefor use in a flooring system as recited in claim 32, wherein thecontinuous sheet is cut to the appropriate length to fit the spacerequirements.
 34. The substrate for use in a flooring system as recitedin claim 32, wherein the substrate has the strength characteristicsrequired to support the decorative layer while having sufficientresiliency to allow the substrate to be delivered in rolls.
 35. Thesubstrate for use in a flooring system as recited in claim 32 whereinthe substrate comprises an SBR rubber material.
 36. A method forinstalling a flooring system comprising a subfloor, a decorative toplayer, and a substrate having a top surface and an oppositely facingbottom surface, said method comprising: positioning the bottom surfaceof the substrate proximate the subfloor, the substrate having voidswhich extend between the top surface and the bottom surface, thesubstrate being manufactured from rubber in sheets which are cut to thedesired configuration and having strength characteristics to support thedecorative layer and prevent damage thereto and sound dampeningcharacteristics to provide decibel reduction through the substrate; andpositioning the decorative top layer proximate the top surface of thesubstrate, wherein the substrate is fixed to the decorative top layer bymeans of an adhesive.
 37. The method as recited in claim 36, wherein thedensity of the substrate is less than 1000 kilograms per meter cubed.38. The method as recited in claim 36, wherein the substrate has thestrength characteristics required to support the decorative layer whilehaving sufficient resiliency to allow the substrate to be delivered inrolls.
 39. The method as recited in claim 36, wherein the substrate isfixed to the subfloor by means of an adhesive.
 40. The method as recitedin claim 36, wherein the substrate comprises an SBR rubber material. 41.The method as recited in claim 36, wherein the sound dampeningcharacteristics exhibit a decibel reduction of about 20 dB for asubstrate with a thickness of 5 mm.
 42. The method as recited in claim36, wherein the substrate comprises rubber and polyurethane.
 43. Themethod as recited in claim 36, wherein the voids are provided betweenparticles of rubber.
 44. The method as recited in claim 36, wherein saidsubstrate comprises rubber and polyurethane.
 45. The method according toclaim 36, further comprising providing the substrate in the form of arolled sheet.
 46. The method according to claim 45, wherein the rolledsheet is four feet wide.
 47. The method as recited in claim 36, whereinthe sound dampening characteristics exhibit a decibel reduction of about25 dB for a substrate with a thickness of 10 mm.
 48. The method asrecited in claim 36, wherein the flooring system has sound dampeningcharacteristics providing a decibel reduction of about 20 dB for asubstrate having a thickness of 5 mm and about 25 dB for a substratehaving a thickness of 10 mm.
 49. The method according to claim 36,wherein the positioning a decorative layer includes positioning thedecorative layer directly on the substrate.
 50. The method according toclaim 36, wherein the substrate is a non-vulcanized substrate.